EP0238444B1 - Laminé composé avec couche de surface en pierre naturelle - Google Patents

Laminé composé avec couche de surface en pierre naturelle Download PDF

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Publication number
EP0238444B1
EP0238444B1 EP87810148A EP87810148A EP0238444B1 EP 0238444 B1 EP0238444 B1 EP 0238444B1 EP 87810148 A EP87810148 A EP 87810148A EP 87810148 A EP87810148 A EP 87810148A EP 0238444 B1 EP0238444 B1 EP 0238444B1
Authority
EP
European Patent Office
Prior art keywords
thickness
pair
metal foils
core
composite laminate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP87810148A
Other languages
German (de)
English (en)
Other versions
EP0238444A2 (fr
EP0238444A3 (en
Inventor
Chesley D. Clem
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
3A Composites International AG
Original Assignee
Alusuisse Lonza Services Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Alusuisse Lonza Services Ltd filed Critical Alusuisse Lonza Services Ltd
Priority to AT87810148T priority Critical patent/ATE73190T1/de
Publication of EP0238444A2 publication Critical patent/EP0238444A2/fr
Publication of EP0238444A3 publication Critical patent/EP0238444A3/en
Application granted granted Critical
Publication of EP0238444B1 publication Critical patent/EP0238444B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/041—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/06—Natural ornaments; Imitations thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/144—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of marble or other natural stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/04—Tiles for floors or walls

Definitions

  • the present invention relates to a composite laminate 10 comprising a polymeric sheet-like core having a pair of surfaces, a pair of metal foils uniformly bonded to said pair of surfaces of said polymeric sheet-like core so as to form a sandwich-type structure, the core having a thickness of from about 0.125 to about 35 mm.
  • a composite is known from US-A-3 382 136.
  • the composite laminate is for use in the paneling of walls, ceilings and other surfaces such as furniture and the like.
  • Natural stone such as marble and the like, is a highly desirable surface material due to its beauty, hardness and durability.
  • use of natural stone as a facing material has been greatly limited due to reasons of expense and weight.
  • US-A-3 723 233 disclosed the manufacture of a laminate comprising marble bonded to a metal honeycomb structure. While the laminate of the ′233 patent was less expensive and lighter than using plain marble facing, the product was still quite expensive and heavy.
  • US-A-3 963 846 discloses an improvement over the ′233 patent in that the multicellular metal core is replaced by a multicellular paper core which is considerably cheaper to produce than the metal core of the ′233 patent. While the improved product of the ′846 patent is inexpensive to manufacture relative to the product of the ′233 patent, the product fails to exhibit the necessary strength and fire resistance for many construction applications.
  • Both US-A-3 382 136 and GB-A-1 577 905 disclose a composite laminate comprising a polymeric sheet-like core having a pair of surfaces and a pair of metal foils uniformly bonded to said pair of surfaces of said polymetic sheet-like core so as to form a sandwich-type structure, whereby the ′136 patent discloses a core thickness of from about 0,125 to about 35 mm.
  • a composite laminate comprising the features of claim 1. Further characteristics of the invention are disclosed in claims 2 to 8.
  • a lamina of natural facing stone is uniformly bonded to at least one of the metal foils which form a sandwich-type structure with the polymeric core.
  • the composite laminate of the present invention exhibits excellent strength properties and fire restistance.
  • the composite laminate of the present invention and the process for manufacturing same offer considerable advantages over heretofore commercially available composite laminates.
  • the composite laminate 10 of the present invention comprises a sandwich-type structure having a polymeric sheet-like core 12 having a pair of metal foils 14 and 16 uniformly bonded to the surfaces of the sheet-like core.
  • a lamina natural facing stone 18 is uniformly bonded to at least one of the metal fils 14 and 16.
  • the composite laminate of the present invention comprises a polymeric sheet-like core having a thickness of from about 1.95 to 5.9 mm (.078 to .236 inches), preferably 3.925 to 4.925 mm (.157 to .197 inches), laminated on both surfaces thereof with metal foils having a thickness of about between 0.375 to 1.0 mm (.015 to .040 inches), preferably between 0.45 to 0.55 mm (.018 to .022 inches), such that the total thickness of the sandwich-type structure is from about 2.33 to 6.45 mm (0.093 to .258 inches), preferably 4.38 to 5.48 mm (.175 to .219 inches).
  • a lamina of natural facing stone is bonded to at least one of the metal foils forming the sandwich-type structure.
  • the thickness of the lamina of natural facing stone is from about 1.55 to 6.25 mm (.062 to .250 inches), preferably 3.125 to 4.675 mm (.125 to .187 inches).
  • the ratio of thickness of the lamina of natural facing stone to the total thickness of the pair of metal foils be from about 2:1 to 4.25:1, preferably 3.125:1 to 3.5:1.
  • the ratio of the thickness of the lamina of natural facing stone to the thickness of the sandwich-type structure is from about 1:1 to 1:1.5, preferably 1:1.17 to 1:1.40.
  • the ratio of the thickness of the polymeric sheet-like core to the thickness of each of the metal foils is from about 7.8:1 to 8.9:1, preferably 5.9:1 to 8.7:1.
  • the composite laminate of the present invention can be prepared in a number of convenient manners.
  • the polymeric sheet-like core is secured to the metal foils using adhesives as for example epoxy resins and the like.
  • the surfaces of the thermoplastic core material and/or the metal foil can be pretreated if desired mechanically, chemically, thermally and electrically in order to improve bonding.
  • Suitable polymeric sheet-like cores include but are not limited to olefinic thermoplastic polymers such as polyethylene, polypropylene, copolymers and terpolymers thereof, as for example, copolymers of ethylene and ethyl acrylate; polyamides, polyhydroxyethers, vinyls and the like.
  • the exposed surface of the metal foils to which the natural facing stone is to be bonded is roughened as for example with a mechanical brush so as to remove any metal oxide coating and increase the bonding area. It is preferred that the roughened surface of the metal foils be roughened until vertical dimensions of 10 ⁇ m to 30 ⁇ m in peaks are obtained.
  • a slurry comprising 70 to 80 percent by weight natural facing stone and 20 to 30% of a matrix material is prepared. Suitable matrix materials include polyesters and epoxys as well as acrylics.
  • the roughened metal surface may be primed with an acrylic primer to a thickness of between 12.5 ⁇ m to 37.5 ⁇ m (.0005 to .0015 inches) and thereafter the slurry is poured onto the exposed and, if desired, primed surface of the metal foil and smoothed.
  • the slurry may be smoothed by troweling or vibrating the sandwich-like structure. It is preferred that this operation take place under reduced pressure in a pressure range of less than 0.74 bar (3/4 atmospheric pressure) in order to eliminate entrapped air in the slurry.
  • the slurry is thereafter cured in air for about 18 to 24 hours at a humidity of from about 40% to 60% at a temperature of between 33 to 42°C (60° to 75°F) so as to set the matrix. Thereafter the laminate of natural facing stone can be polished to a high gloss.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Laminated Bodies (AREA)
  • Cultivation Receptacles Or Flower-Pots, Or Pots For Seedlings (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Claims (8)

1. Stratifié composite (10) comprenant un noyau polymérique en forme de feuille (12) comportant deux surfaces, deux feuilles métalliques (14, 16) liées uniformément auxdites deux surfaces dudit noyau polymérique en forme de feuille de manière à former une structure de type sandwich, le noyau (12) ayant une épaisseur d'environ 0,125 à environ 35 mm, caractérisé en ce que
a) une couche de pierre naturelle de parement (18) est liée uniformément à aux moins l'une desdites feuilles métalliques (14, 16),
b) l'épaisseur dudit noyau polymérique en forme de feuille (12) est comprise entre 1,95 et 5,9 mm,
c) l'épaisseur de chacune desdites feuilles métalliques (14, 16) est comprise entre 0,375 et 1,0 mm,
d) l'épaisseur de ladite couche de pierre naturelle de parement (18) est comprise entre 1,35 et 6,25 mm, et
e) le rapport de l'épaisseur de la couche de pierre naturelle de parement (18) à l'épaisseur totale desdites feuilles métalliques (14, 16) est compris entre 2:1 et 4,25:1.
2. Stratifié composite (10) selon la revendication 1, caractérisé en ce que le rapport de l'épaisseur de la couche de pierre naturelle de parement (18) à l'épaisseur de ladite structure de type sandwich est compris entre 1:1 et 1:1,5.
3. Stratifié composite (10) selon la revendication 1, caractérisé en ce que le rapport de l'épaisseur dudit noyau polymérique en forme de feuille (12) à l'épaisseur de chacune desdites feuilles métalliques (14, 16) est compris entre 7,8:1 et 8,9:1.
4. Stratifié composite (10) selon la revendication 3, caractérisé en ce que le rapport de l'épaisseur de la couche de pierre naturelle de parement (18) à l'épaisseur de ladite structure de type sandwich est compris entre 1:1,2 et 1:1,4.
5. Procédé de fabrication d'un composite (10) selon les revendications 1 à 4, caractérisé par les étapes consistant à :
a) former ladite structure de type sandwich en liant lesdites feuilles métalliques (14, 16) auxdites surfaces dudit noyau polymérique en forme de feuille (12) ;
b) rendre rugueuse la surface exposée d'au moins l'une desdites feuilles métalliques (14, 16) afin de retirer tout revêtement d'oxyde métallique et d'augmenter la surface de liaison ;
c) préparer une suspension comprenant 70 à 80 % de pierre naturelle de parement et 20 à 30 % d'un matériau formant matrice choisi dans le groupe formé par les polyesters, les résines époxy et/ou acryliques ;
d) verser et lisser ladite suspension sur ladite surface exposée d'au moins l'une desdites feuilles métalliques (14, 16) ; et
e) durcir à l'air ladite matrice versée et lissée pour la faire prendre.
6. Procédé selon la revendication 5, caractérisé par les étapes consistant à appliquer sur ladite surface exposée d'au moins l'une desdites feuilles métalliques (14, 16) une couche de fond acrylique jusqu'à une épaisseur comprise entre 12,5 et 37,5 µm (0,0005 et 0,015 pouce) avant de verser et lisser ladite suspension.
7. Procédé selon la revendication 5, caractérisé en ce que les étapes consistant à verser et à lisser ladite suspension se déroulent dans un environnement sous pression réduite inférieure à 0,74 bar (3/4 de pression atmosphérique).
8. Procédé selon la revendication 7, caractérisé en ce que les étapes consistant à durcir ladite matrice à l'air se déroulent à une température comprise entre 33 et 42°C (60 et 75°F) et à une humidité comprise entre 40 et 60 % pendant 18 à 24 h.
EP87810148A 1986-03-21 1987-03-13 Laminé composé avec couche de surface en pierre naturelle Expired - Lifetime EP0238444B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AT87810148T ATE73190T1 (de) 1986-03-21 1987-03-13 Zusammengesetztes laminat mit oberschicht aus naturstein.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US842162 1986-03-21
US06/842,162 US4664955A (en) 1986-03-21 1986-03-21 Natural stone facing composite laminate

Publications (3)

Publication Number Publication Date
EP0238444A2 EP0238444A2 (fr) 1987-09-23
EP0238444A3 EP0238444A3 (en) 1989-03-22
EP0238444B1 true EP0238444B1 (fr) 1992-03-04

Family

ID=25286675

Family Applications (1)

Application Number Title Priority Date Filing Date
EP87810148A Expired - Lifetime EP0238444B1 (fr) 1986-03-21 1987-03-13 Laminé composé avec couche de surface en pierre naturelle

Country Status (5)

Country Link
US (1) US4664955A (fr)
EP (1) EP0238444B1 (fr)
AT (1) ATE73190T1 (fr)
CA (1) CA1296586C (fr)
DE (1) DE3776929D1 (fr)

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US8166783B2 (en) 2007-02-23 2012-05-01 Master Lock Company Llc Anti-tampering arrangements for pin tumbler cylinder locks

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US8782989B2 (en) 2009-06-11 2014-07-22 Comc, Llc Narrow lined modular flooring assemblies
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Publication number Priority date Publication date Assignee Title
US8166783B2 (en) 2007-02-23 2012-05-01 Master Lock Company Llc Anti-tampering arrangements for pin tumbler cylinder locks

Also Published As

Publication number Publication date
EP0238444A2 (fr) 1987-09-23
US4664955A (en) 1987-05-12
DE3776929D1 (de) 1992-04-09
EP0238444A3 (en) 1989-03-22
ATE73190T1 (de) 1992-03-15
CA1296586C (fr) 1992-03-03

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